Lexmark 4039-1XX - Manuals

Table of Contents vii 4039-1XX Removals (continued) Operator Panel Removal............................................................. 84Option Card Removal.................................................................. 84Exit Sensor Removal..........................................................

viii Service Manual 4039-1XX Preventive Maintenance ....................................................... 119 Safety Inspection Guide ............................................................ 119Lubrication Specifications.......................................................... 120Printhead Wi...

Notices and Safety Information ix 4039-1XX Notices and Safety Information References in this publication to products, programs, or services do not imply that the manufacturer intends to make these available in all countries in which it operates. Any reference to a product, program, or service is not...

x Service Manual 4039-1XX The manufacturer is not responsible for any radio or television interference caused by using other than recommended cables or by unauthorized changes or modifications to this equipment. Unauthorized changes or modifications could void the user’s authority to operate the equ...

Notices and Safety Information xi 4039-1XX European Community (EC) Electromagnetic Compatibility Directive This product is in conformity with the protection requirements of EC Council directive 89/336/EEC on the approximation of the laws of the Member States relating to electromagnetic compatibility...

xii Service Manual 4039-1XX Safety Information • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others. • There may be an increased risk of electric shock and personal injury during disassembly and servicing o...

Notices and Safety Information xiii 4039-1XX Norme di sicurezza • Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale dell'assistenza autorizzato. • Durante lo smontaggio e il manutenzionamento di questo prodotto, è possibile il rischio accresciuto d...

xiv Service Manual 4039-1XX Preface This manual is divided into the following chapters: • “General Information” contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental ...

General Information 1 4039-1XX General Information The 4039 is a family of 600 dpi Laserprinters designed to attach to IBM-compatible PC’s and to most types of computer networks. The printer has PostScript and PCL emulation standard. Models Covered in this Manual There are no voltage or pinout diffe...

2 Service Manual 4039-1XX Lexmark Model 4039-10 plus (Called 10P in this manual and on the serial number plate) 10ppm, PostScript Level 2 emulation, no serial port, torquer motor rather than paper pick solenoid, and service error log Options The following options are available. Some options are not ...

General Information 3 4039-1XX Maintenance Approach The diagnostic information in this manual will lead you to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom index, service checks, and diagnostic aids to determine the symptom and repair the failure. See “Diagnos...

Diagnostic Information 5 4039-1XX Diagnostic Information 4039 Diagnostics: Failures With Error Codes Two-digit codes are messages for the 4039 user, but if they recur frequently or at inappropriate times they may be symptomatic of a service problem. On “plus” models, refer to the diagnostics error l...

Diagnostic Information 11 4039-1XX Power-On Self Test (POST) When you turn the printer on, it performs a Power-On Self Test. Check for correct POST functioning by observing the following: 1. 1½ rows of pels appear on the display and then clear. 2. Diamonds fill the display and then clear. 3. The fus...

12 Service Manual 4039-1XX Symptom Table Symptom Action or Service Check Dead Machine Dead Machine Service Check Repeats pattern of five beeps and a pause. Operator Panel Service Check Machine Hangs Displaying Diamonds Machine Hangs Displaying Diamonds Service Check Operator Panel Operator Panel Ser...

Diagnostic Information 13 4039-1XX Banding Banding appears as light and dark horizontal lines on a page that is supposed to be uniformly gray. It is due to variation in the speed of the paper as it moves from roll to roll during development or transfer. It is undetectable when printing text and is m...

14 Service Manual 4039-1XX . If any voltages are not correct replace the system board. Note: “Contrast” on the Diagnostics menu (changed to “Transfer” on 4039 plus machines) does not adjust the print contrast but changes the transfer algorithm slightly. Users who run large jobs with very dense graph...

Diagnostic Information 15 4039-1XX Black Page Black output is usually caused by an incorrect high voltage in the printing process, resulting in toner development on the entire photoconductor drum. Check the condition of each HVPS contact and make sure they spring back when pressed. Check the continu...

16 Service Manual 4039-1XX Blank Page Inspect the printhead shutter for proper operation and make sure the actuator on top of the cartridge is present and extends into the printhead shroud when the printer top cover is closed. A failed printhead will cause a 931 Service error rather than blank outpu...

Diagnostic Information 17 4039-1XX . If the voltages are not correct replace the system board. Blurred or Fuzzy Print This can be caused by a damaged gear train or by paper slippage in the feed roll or transfer roll. Also see “Banding” on page 13. Inspect the HVPS contacts; make sure each spring-loa...

18 Service Manual 4039-1XX If some voltages are present, but all are not correct, disconnect all cables except the LVPS from the system board. POR and verify that the LVPS voltages are correct. Turn the power back off and, one at a time, reconnect the system board cables, powering on in between each...

20 Service Manual 4039-1XX Fuser Theory The fuser lamp operates off line voltage from the LVPS. The thermistor is in contact with the fuser hot roll. The system board reads the thermistor resistance and toggles a TRIAC in the LVPS which cycles the lamp on and off to maintain the proper hot roll temp...

Diagnostic Information 21 4039-1XX If the thermal fuse has blown, the fuser and the fuser wiper will be damaged. Before replacing the fuser and the fuser wiper, check the voltage at (10P) J11-16 (10R/12R/12C/12L) J11-3 (16L)J18-16 as you POR again. It should stay at 0 until the 922 Error is displaye...

22 Service Manual 4039-1XX Horizontal Void or Streak This is usually due to the cartridge not being installed correctly. Check the printhead area for obstructions, and check the mechanical workings of the print cartridge and printhead shutter. If nothing is found go to “Blank Page” and follow those ...

Diagnostic Information 23 4039-1XX PostScript emulation output may appear lighter than PCL output or a test print; this is not a defect. Verify on the Print Test that the print is too light before performing service. Network Card 977 Errors All network card errors are recorded as 977 in the error lo...

24 Service Manual 4039-1XX For handle-mounted sensor: The voltage at sensor card J2-3 (pin 1 is the bottom pin) should be +5VDC, and the voltage at J2-4 should be (12L) 10 to 14VDC (16L) 22 to 26VDC. If these are incorrect and the cable has continuity, replace the system board. The voltage between J...

Diagnostic Information 25 4039-1XX On models 10R/12R/12C/12L, a DC-DC convertor changes +34VDC at J9-1 into +5VDC, +12VDC, and -12VDC. Check for +5VDC at J8-1 and for +34VDC at J9-1 and at J11-4. Replace the DC-DC convertor, the system board, or the LVPS depending on where the voltage is incorrect. ...

26 Service Manual 4039-1XX If paper feeds but stops undamaged in the paper path there may be a sensor problem. Run the diagnostic test for the input and exit sensors replace as necessary. Check the continuity of the cable before replacing the sensor. The input sensor signal is on (10P) J20-6 (10R/12...

Diagnostic Information 27 4039-1XX Paper Feed Problem, Envelope+ Feeder/100-Sheet Auxiliary Feeder Check for the following: paper or envelope jammed in the feed path; missing hold-down weight; adjustable guide out of position; feeder cable loose, disconnected, or plugged in the wrong connector; feed...

28 Service Manual 4039-1XX Paper Size Sensing Problem (The printed area does not fit on the page, or the paper size cannot be changed from the operator panel.) Make sure that paper trays for the 4019, 4028, or 4029 are not being used in the 4039 printer. Make sure the paper tray and its stops are un...

Diagnostic Information 29 4039-1XX Regularly Spaced Marks This is caused by a defect on one of the rolls or gears in the print process. The damaged part can be determined by the spacing of the marks according to the following table. Find and replace the damaged part. Spacings other than the ones lis...

30 Service Manual 4039-1XX Random Marks Random marks are nearly always due to a mechanical problem or due to foreign matter loose in the printer or in the print cartridge. Inspect and clean the inside of the printer carefully and correct any problems found. Skew, all edges If the test print frame is...

Diagnostic Aids 32 4039-1XX Diagnostic Aids Diagnostics Mode To run some of the printer diagnostic tests described in this chapter, you must put the printer in Diagnostics mode. To enter Diagnostics mode: 1. Turn the printer off. 2. Press and hold the Ready and Return buttons. Then turn the printer ...

Diagnostic Aids 33 4039-1XX Grouped Diagnostic Aids Print Tests Operator Panel Tests Print Test Page Button Test Developed Image Test LCD Test Print Tests Duplex Tests Registration Tests Duplex Feed 1Duplex Feed 2 Print RegistrationQuick Test Paper Feed Tests Page Counts Envelope Print Test Page Cou...

34 Service Manual 4039-1XX Alphabetical List of Diagnostic Aids Auto Clean Auto Clean needs to be turned on if there is an unacceptable amount of toner being deposited on the back of the page. When Auto Clean is on, after printing the number of pages specified in Auto Clean Frequency, the printer pa...

36 Service Manual 4039-1XX A message describing test progress is displayed during the test. 1. Enter Diagnostics mode. 2. Select [Device Test] 3. Select [Disk Test/Clean]. 4. Select [CONTINUE] to start the test, or [CANCEL] to return to Diagnostics mode main menu. 5. Select [CANCEL] to interrupt the...

Diagnostic Aids 37 4039-1XX Duplex Feed 2 Test This test verifies that paper feeds through the duplex unit properly and tests the stop point of the page as it feeds back over the top of the duplex paper tray. 1. Enter Diagnostics mode. 2. Select [Duplex Tests]. 3. Select [Duplex Feed 2]. 4. Select [...

38 Service Manual 4039-1XX Envelope Enhance Use this procedure to set the fuser solenoid power level to low, medium, or high. Increase the level to reduce envelope wrinkling, or decrease the level to reduce solenoid noise. 1. Enter Diagnostics mode. 2. Select [Envelope Enhance]. 3. Select [Low], [Me...

Diagnostic Aids 39 4039-1XX Fuser Temperature And Warm-Up Time These settings allow adjustment of the fuser to correct problems with paper curl or melting letterheads. Paper curl in which the top and bottom of the page curl toward the printed side (hot paper curl) can be corrected by reducing the fu...

40 Service Manual 4039-1XX Maintenance Kit Count This non-displayed counter must be reset after the maintenance kit is replaced to prevent the [80 Scheduled Maintenance] message from displaying when the machine is turned on. 1. Enter Diagnostics mode. 2. Select [Maintenance Count]. 3. Select [RESET]...

Diagnostic Aids 41 4039-1XX LCD Test To test the operator panel display: 1. Enter Diagnostics mode 2. Select [LCD Test]. 3. Select [Single] or [Continuous]. 4. The display goes through a continuous sequence of turning pels on and off. 5. Press Return to stop continuous LCD test. 6. Press Return to r...

42 Service Manual 4039-1XX Permanent Page Count The permanent page count can be displayed only. It cannot be modified or reset by the customer or servicer. 1. Enter Diagnostics mode. 2. Select [Permanent Page Count]. 3. Press Return to return to Diagnostics mode main menu. Print Contrast (Transfer o...

Diagnostic Aids 43 4039-1XX 4. Select [Print Test Page]. 5. Select either [Single] or [Continuous] depending if you want one page or continuous test pages. 6. Select [Stop] when you want the continuous test to end. Print Tests All of the print tests can be run in the [Single] or [Continuous] mode. T...

44 Service Manual 4039-1XX Print Test 3 This test generates 2 printouts: a solid black page, and a dot pattern that can be used to evaluate print quality. 1. Enter Diagnostics mode. 2. Select [Print Test 3]. 3. Select [Single] or [Continuous]. 4. Select [CANCEL] to stop continuous print. 5. Press Re...

Diagnostic Aids 45 4039-1XX Sensor Test 1. Enter Diagnostics mode. 2. Select [Sensor Test]. 3. Select one of the following sensor tests. • Toner Low • Output Bin • Input • Exit • Cover Open Note: The Output Bin sensor can have up to a 15 second delay in changing to open. 4. When the sensor is blocke...

46 Service Manual 4039-1XX Network Connections and Checks Wrap Tests The Wrap Tests check the circuits used to communicate with the host computer. To run the Wrap Test: 1. Turn the printer off. 2. Disconnect the interface cable. 3. Install the wrap plug in one of the interface cable connectors. Note...

Diagnostic Aids 47 4039-1XX LAN Information The printer may be connected to one of the following LAN types: Token-Ring Ethernet 10BaseT Ethernet 10Base2 LocalTalk The Network external connectors are pictured below. The printer test page also indicates to which type of LAN the printer is connected. S...

Diagnostic Aids 49 4039-1XX Switch 8 – Buffer Size: Switch 8 allows the adapter buffer size to be limited, to minimize the amount of data in the buffer at any time. Switch 9 – Protocol: Switch 9 selects the type of protocol. Switch 10 - Print Test: Switch 10 selects the print test for the serial int...

Repair Information 51 4039-1XX Repair Information This chapter explains how to make adjustments to the printer and how to remove defective FRUs. Handling ESD-sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-s...

52 Service Manual 4039-1XX Adjustments Envelope Restraint Spring On The Envelope+ Feeder 1. Loosen the mounting screw [A]. 2. Position the spring [B] so it clears the separator roller by 1.9 ±0.2 mm (0.075 ±0.008 in.). 3. Tighten the mounting screw. Paper Restraint Spring On The 100-sheet Auxiliary ...

54 Service Manual 4039-1XX Fuser Drive Gear Backlash Fuser drive gear backlash is adjusted so that when gear #2 is held still, there is a slight amount of backlash in the fuser gear. Print quality can be affected if the gears are too tight. 1. Remove the fuser cover. 2. Locate gear #2. It is the whi...

56 Service Manual 4039-1XX Fuser Solenoid Note: The fuser solenoid must be mounted on the fuser for this adjustment and should be at room temperature. 1. Loosen screw [A]. 2. Remove the rubber washer. 3. Rotate shaft [B] (eccentric) to obtain 4.2 mm ± 0.2 mm (0.165 in.± 0.008 in.) air gap. 4. Tighte...

Repair Information 57 4039-1XX Paper Feed Magnet 1. Remove the system board. The magnet is accessed through the holes in the right frame. 2. With the armature latched on the cam step check for 0.60 mm ± 0.07 mm (0.024 in ± 0.003 in.) between the foam pad and the magnet pole piece. If adjustment is r...

58 Service Manual 4039-1XX Optional Paper Feed Magnet 1. With the armature latched on the cam step check for 0.60 mm ± 0.07 mm between the foam pad and the magnet pole piece. If adjustment is required, continue: 2. Keep the armature latched and loosen the magnet mounting screw [A]. Note: The flat si...

Repair Information 59 4039-1XX Printhead Skew - Level 1 1. Loosen the mounting screws [A]. 2. Pivot the printhead around the shoulder screw [B] until the skew marks on the printout are parallel to the top edge of the paper. Use Print Test 1 or Quick Test to check this. Rotating the printhead clockwi...

60 Service Manual 4039-1XX Printhead Skew - Level 2 1. Remove the top cover. 2. Loosen the screws [A]. 3. Run Print Test 1 or the Quick Test on the Diagnostics Menu. 4. Move the pointer [B] to eliminate the skew. Moving the pointer toward the left raises the left adjustment point on the printout. 5....

Repair Information 61 4039-1XX Print Registration Adjustment Use Print Test 1 or the Quick Test to evaluate print registration. Adjust the registration so the tips of the diamonds are at the top and bottom edges of the page and the printout is centered left to right. Verify that the to Top Margin is...

62 Service Manual 4039-1XX Removals When there is artwork to support a procedure, it follows the text. Covers Right Cover Removal 1. Turn the printer off. 2. Remove all external trays. 3. Open the top cover. 4. Swing the cover open. 5. Remove the E-clip from the rear pivot pin and lift the cover off...

66 Service Manual 4039-1XX Transfer Roll Removal 1. Unplug the power cord. 2. Remove the print cartridge. 3. Remove the bearing cover from the left side of the transfer roll: Note: Do not touch the transfer roll surface. • Support the left bearing cover from the front with your left hand. • Use a sm...

Repair Information 67 4039-1XX D-roll Assembly Removal 1. Unplug the power cord. 2. Remove the paper tray. Note: The following 3 steps are not necessary, but may make it easier to see the parts. 3. Remove the print cartridge. 4. Remove the fuser input guide. 5. Remove the transfer roll housing assem...

68 Service Manual 4039-1XX Drive Motor Removal 1. Unplug the power cord. 2. Remove the system board. 3. Remove the system board inner EMC shield. 4. Remove the fuser input guide [A]. 5. Remove the transfer housing assembly. 6. Remove the gear cover by releasing the rear latch and lifting up. 7. Remo...

74 Service Manual 4039-1XX Fuser Lamp Removal CAUTION: THE TEMPERATURE OF THE HOT ROLLER IS 150 °-230 ° C (302 °-446 ° F). USE EXTREME CAUTION WHEN REMOVING THIS UNIT. BEFORE YOU SERVICE THIS UNIT, ALLOW THE MACHINE TO COOL FOR 5 MINUTES. Note: The fuser lamp is a glass heater. Do not touch the lamp...

Repair Information 75 4039-1XX Fuser Solenoid Removal 1. Remove the fuser. 2. Remove the two mounting screws [A] holding the solenoid housing to the fuser housing. 3. Disengage the solenoid bracket from the plunger. Note: When a new solenoid assembly is installed, the fuser solenoid must be adjusted...

76 Service Manual 4039-1XX Fuser Thermistor Removal 1. Disconnect the thermistor cable connector [A] from the exit sensor card. 2. Remove the fuser cover and wiper. 3. Remove the tape holding the thermistor cable to the shroud. 4. Squeeze the thermistor bracket tabs [B] and remove the thermistor fro...

78 Service Manual 4039-1XX HVPS Removal 1. Unplug the power cord. 2. Remove the left cover 3. Remove the fuser input guide. 4. Remove the transfer roll housing. 5. Remove the fuser cover. 6. Disconnect the cable from the HVPS connector. 7. Remove the power switch rod. 8. Remove the ground screw [B]....

80 Service Manual 4039-1XX Input Sensor Removal 1. Remove the fuser input guide [A]. 2. Remove the transfer roll housing. 3. Remove the D-roll. 4. Disconnect the system cable from the input sensor board. Note: Use care, the flag can be damaged while removing the sensor. 5. Release latch [B] and pull...

Repair Information 81 4039-1XX Lower Frame Assembly Removal 1. Remove the right, front, and left covers 2. Remove the LVPS and the rod for the on/off switch. 3. Remove gear cover and the fuser input guide [A]. 4. Remove the transfer roll housing. 5. Disconnect the cable from the HVPS. 6. Remove the ...

82 Service Manual 4039-1XX LVPS Removal 1. Disconnect the power cord. 2. Remove all external feed trays. 3. Remove the left and right side covers. 4. (10P and 16L) remove the system board and the inner EMC shield. 5. Remove the left and right LVPS mounting screws. 6. Disconnect the fuser connector [...

Repair Information 83 4039-1XX LVPS Cover Removal 1. Form tabs [D] away from the power supply to create clearance for tabs [A] to move downward. 2. Release the top latches [A]. 3. Release the side latches [B]. 4. Release the bottom latches [C].

84 Service Manual 4039-1XX Operator Panel Removal 1. Remove the top cover. 2. Disconnect the operator panel cable. 3. Remove the operator panel mounting screws from the inside of the top cover. Option Card Removal 1. Remove all external trays. 2. Open the top cover. 3. Open the right cover. 4. Remov...

Repair Information 85 4039-1XX Exit Sensor Removal 1. Remove the front cover. 2. Disconnect the fuser/sensor cable. 3. Disconnect the thermistor cable. 4. Disconnect the fuser solenoid cable. This cable is not present in all models. 5. Release the latches [A]. 6. Pull the sensor down to remove it.

86 Service Manual 4039-1XX Paper Feed Magnet Assembly Removal 1. Remove the print cartridge. 2. Remove the right cover. 3. Remove the system board. 4. Remove the inner EMC shield. 5. Locate the paper feed magnet mounting screw [B] (visible through the right side frame [A]). 6. Remove the mounting sc...

Repair Information 87 4039-1XX Paper Feed Rollers Removal Note: Replace all paper feed drive rollers at the same time. 1. Remove the lower frame. 2. Disconnect the system cable from the input sensor. 3. Remove the screws [A] and the outer deflector. 4. Remove the screws [B] and the toner shield [E]....

88 Service Manual 4039-1XX Paper Size Switch Removal 1. Open the top cover. 2. Remove the print cartridge. 3. Remove the paper tray. 4. Open the right side cover. 5. Remove the front cover. 6. Remove the two screws [A]. 7. Unplug the cable [B] from the switch connector [C]. 8. Rotate the switch abou...

Repair Information 89 4039-1XX Printhead Removal IMPORTANT: The printhead is ESD-sensitive. It is not serviceable and should be replaced as a unit. 1. Turn the printer off. 2. Remove the print cartridge. 3. Remove the right and top covers. 4. Remove the exit redrive and its belt. 5. Remove the air p...

90 Service Manual 4039-1XX System Board Removal 1. Check the page count and write it down so you can set the new system board. 2. Turn the printer off. 3. Remove the right cover. 4. Remove the outer EMC shield by pressing down on the two bottom tabs, slide the shield forward, then down (10P has no o...

Repair Information 93 4039-1XX Toner Sensor Removal 1. Remove the fuser input guide [A] 2. Remove the transfer roll housing. 3. Lift the input sensor board far enough to disconnect the cable [B]. 4. Remove the end of the bellcrank spring. 5. Lift the sensor to unsnap it. 6. Work the cable out of the...

94 Service Manual 4039-1XX Transfer Roll Housing Removal 1. Remove the print cartridge. 2. Remove the fuser input guide. 3. Grasp the housing and pull toward the front of the machine to disconnect the housing from the mounting studs, visible through openings [B] in the inner deflector. 4. Lift the t...

Repair Information 95 4039-1XX Upper Frame Removal 1. Unplug the power cord. 2. Remove the print cartridge. 3. Remove the right, left, and top covers. 4. Remove the system board. 5. Remove the inner EMC shield. 6. Remove the load box latches [A]. 7. Release the latches [B]. 8. Pivot the upper frame ...

96 Service Manual 4039-1XX Zif Connector Removal 1. Slide the cable clamp [A] to the open position. 2. Note how the contact surfaces [C] of the cable are positioned as you pull the cable [B] out of the connector.

Repair Information 97 4039-1XX Duplex Option Top Cover And Table Cover Removal 1. Open the top cover by pulling up at [A] and pivoting 90 °. 2. Pry the top cover from the bottom cover at [B] and lay the top cover on its side. 3. To disconnect the fan leads, the table cover has to be removed. 4. Rele...

98 Service Manual 4039-1XX Duplex Option Exit Card And Cover Removal 1. Pry up on tabs [A], after the tabs are released, lift up on the cover, rotate the cover out, and slide it to the right to completely remove it. 2. Disconnect the exit sensor card cable. 3. Depress the exit sensor flag actuator [...

100 Service Manual 4039-1XX Duplex Option System Card And Motor Removal 1. Disconnect all cables. 2. Release latches [A] and lift the system board out. 3. Remove the two motor mounting screws [B]. 4. Lift the motor out of the frame assembly. Note: The remaining FRU is the Gearblock Assembly. When yo...

Connector Locations 101 4039-1XX Connector Locations This chapter shows the locations of major printer assemblies, gears, connectors, and ground straps. Major Assembly Locations Low Voltage Power Supply Output Sensor Paper Tray Operator Panel Fan Exit Redrive Print Head High VoltagePower Supply Fuse...

104 Service Manual 4039-1XX Transfer Roller Housing Paper Guide* * Transfer roller housing for 10P has no paper guide

Connector Locations 105 4039-1XX System Cable System Board(10R/12R/12C/12L) J20(16L) J17 Pin 1 Pin 1 HVPS Input and Toner Sensors Pin 1 Transfer Roll Pin 1

108 Service Manual 4039-1XX System Board Connectors 16L

110 Service Manual 4039-1XX System Board Connectors 10P J21 J14 J11

112 Service Manual 4039-1XX Printhead Cables The printhead cable connector for 10P, 10R, 12R, 12L,and 12C is J6. The printhead cable connector for 16L is J4. Connector

Connector Locations 113 4039-1XX Mirror Motor Cable/Fan Cable The mirror motor cable connector for the 10P, 10R, 12R, 12L, and 12C is J5. The mirror motor cable connector for 16L is J3. Printhead Cable Pin Laser Hsync 1 1 2 2 3 3 4 4 5 6 6 5 7 4 8 3 9 2 10 1 Pin Motor Fan 1 1 2 2 3 3 4 4 5 5 6 2 7 1

116 Service Manual 4039-1XX * No connection on machines with redrive-mounted output bin sensor. Pin Op Panel Sensor 1 1 2 2 3 3 4 4 5 5 6 1 7 2 8 3 9 4 *

Connector Locations 117 4039-1XX Printer Ground Straps Outer Deflectorto Lower Frame HVPS toFrame Operator Panelto Upper Frame Toner Shield toLower Frame Load BoxShaft toUpper Frame Static Brush toLower Frame

Preventive Maintenance 119 4039-1XX Preventive Maintenance This chapter describes procedures for printer preventive maintenance. Following these recommendations can help prevent problems and maintain optimum performance. Safety Inspection Guide The purpose of this inspection guide is to aid you in i...

120 Service Manual 4039-1XX Lubrication Specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use of lubricants other than those specified can cause premature failure. Some unauthorized lubricants may chemically attack polycarbonate parts. Use IBM no.10 oil PN...

122 Service Manual 4039-1XX Printhead Window Cleaning Procedure Do not use cleaning fluids on the printhead window. Do not use a bare cotton swab. The swab deposits lint on the window. Note: The printhead window is a coated glass. Do not push too hard and scratch or break the glass. 1. Remove the pr...

Preventive Maintenance 123 4039-1XX Scheduled Mechanical Maintenance The operator panel will display the message “80 Scheduled Maintenance” at each 200K (100K for 12C) page count interval. It is necessary to replace the fuser assembly, transfer roller, d-roll, and lower redrive shaft assembly at thi...

Parts Catalog 124 4039-1XX Parts Catalog How To Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are broken down on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed sep...

Parts Catalog 129 4039-1XX Assembly 2: Lower Frame 7 1 14 1 20 22 3 19 6 11 1 18 2 15 13 12 8 9 9 7 23 17 5 10 4 4A

Parts Catalog 133 4039-1XX Assembly 3: Upper Frame 1 1A 3 26 14 28 12 4 5 11 24 6 10 30 16 12 2 11 7 8 29 28 20 23 19 23 23 23 18 17 22 21 25 24

Parts Catalog 137 4039-1XX Assembly 4: Printhead System Board 9 2 7 6 4 3 1 8B 8A 8

Parts Catalog 139 4039-1XX Assembly 5: Paper Feed 34 38 16 37 31 36 29 15 21 20 22 14 13 17 2 12 33 4 1 23 26 6 3 18 35 34 35 5 19 24 23 8 8 9 8 25 30 10 23 11 39 28 35 7

Parts Catalog 143 4039-1XX Assembly 6: Paper Feed Alignment Gears

Parts Catalog 145 4039-1XX Assembly 7: Paper Feed Drive 1 5 3 2 20 7 4 22 7 13 12 18 21 8 21 18 11 10 14 19 25 24 23 8 19 6 9 17 15 16

Parts Catalog 159 4039-1XX Assembly 13: Electronics 5A 7 13 6 9 11 5 4A 4 3 18 1 18 23 21 22

Parts Catalog 163 4039-1XX Assembly 14: Transfer Roll

Parts Catalog 165 4039-1XX Assembly 15: Duplex Option 3 7 2 12 13 14 8 19 16 1 18 11 17 10 15 6 5 4

170 Service Manual 4039-1XX Assembly 18: Miscellaneous Asm-Index Part Number Units Description - 1319128 1 Parallel Wrap Plug - 1329048 1 Serial Wrap Plug - 1383313 1 Cables/Jumpers parts packet - 1383314 1 Fasteners parts packet - 1383315 1 Clips parts packet - 1383316 1 Springs parts packet - 1383...

Index 171 4039-1XX Index Numerics 100-sheet auxiliary feeder paper restraint spring adjustment 52 A abbreviations 4 auto clean 34 auto clean delay 34 auto clean frequency 34 B background 13 banding 13 black page 15 blank page 16 blurred or fuzzy print 17 button test 40 C connector locations 101 cove...